JEEP XJ 1995 Service And Repair Manual

(2) Install shift sector in the case (Fig. 48).
(3) Install range lever and lever attaching nut on
shift sector. Tighten attaching nut to 30 Nzm (22 ft.
lbs.) torque.
(4) Install detent plunger, spring and plug (Fig.
49). Tighten plug to 20 Nzm (15 ft. lbs.) torque.
(5) Inspect pads on range fork (Fig. 50). Be sure
pads are secure and in position. Replace fork as an
assembly if pads are worn through, or broken.
(6) Assemble range fork and shift hub (Fig. 51).
(7) Engage range fork pin in shift sector slot (Fig.
52).
(8) Insert shift hub in low range gear. Be sure hub
is fully seated.
Fig. 48 Shift Sector Installation
Fig. 49 Installing Detent Plunger, Spring And Plug
Fig. 50 Range Fork Pad Locations
Fig. 51 Assembling Range Fork And Shift Hub
Fig. 52 Seating Range Fork Pin In Shift Sector Slot
JNP231 TRANSFER CASE 21 - 299

MAINSHAFT ASSEMBLY
(1) If drive sprocket bearings are to be replaced,
remove and install them as follows:
(a) Press both bearings out of sprocket simulta-
neously with Tool Handle C-4171 and Remover Tool
C-4667, or 5066 (Fig. 53).
(b) Before installing new bearings, refer to Figure
54 and note correct bearing position in sprocket. Bear-ings must also be installed in proper sequence. Install
front bearing first and rear bearing last.
CAUTION: Do not press the bearings any farther
into the sprocket than indicated in Figure 54. The
bearings could block the mainshaft oil feed hole if
pressed too deeply into the sprocket.
(c) Install newfrontbearing first. Press bearing
flush with edge of sprocket bore (Fig. 55).
(d) Install newrearbearing (Fig. 56). Press
bearing in until 4.6 mm (3/16 in.) below edge of
bore as shown in Figure 46.
(2) On synchro models, install struts and spring(s)
in hub (Fig. 57).
(3) Lubricate drive sprocket bearings, stop ring
and hub with automatic transmission fluid. Bearings
can also be lubricated with petroleum jelly if desired.
(4) Install sprocket, stop ring (synchro models
only) and hub on mainshaft (Fig. 58).Be sure to
seat hub struts on stop ring lugs.
(5) Install spacer washer on hub, if equipped.
Fig. 54 Correct Bearing Position In Drive Sprocket
Fig. 53 Drive Sprocket Bearing Removal
Fig. 55 Installing Drive Sprocket Front Bearing
Fig. 56 Installing Drive Sprocket Rear Bearing
21 - 300 NP231 TRANSFER CASEJ

(6) Install new hub retaining snap ring (Fig. 59).
MAINSHAFT AND MODE FORK INSTALLATION
(1) Install sleeve on hub. Be sure sleeve is in-
stalled with beveled spline ends facing stop ring and
short end of sleeve toward raer of shaft. In addition,
on synchro models, be sure a sleeve tooth is aligned
with each synchro strut (Fig. 60).
CAUTION: Correct sleeve alignment is important to
proper shifting on synchro models. Be sure a
sleeve tooth is aligned (centered) over each syn-
chro strut (Fig. 60). Gear clash will occur if the
struts and sleeve teeth are misaligned.
(2) Install new pads on mode fork.(3) Engage mode fork in sleeve (Fig. 61).
(4) Install mode fork-mainshaft assembly in case
(Fig. 61). Be sure the mode fork rail is seated in case
bore.
(5) Lift mainshaft upward about 2.54 cm (1-inch).
(6) Position front output shaft in drive chain.
Fig. 57 Installing Synchro Springs And Struts In
Hub
Fig. 58 Sprocket, Stop Ring And Hub Installation
Fig. 59 Installing Hub Retaining Snap Ring
Fig. 60 Correct Synchro Strut And Sleeve Alignment
(Synchro Models Only)
JNP231 TRANSFER CASE 21 - 301

(7) Install chain on drive sprocket and start front
shaft into front bearing at same time (Fig. 62).
(8) Seat mainshaft and front output shaft (Fig. 54).
If front shaft is hard to seat, lift mainshaft slightly to
allow front shaft to seat.
(9) Reseat mainshaft in input gear and seat sleeve
on hub if necessary.
(10) Install mode spring on shift rail (Fig. 63).
OIL PUMP, REAR CASE, REAR RETAINER AND
EXTENSION INSTALLATION
(1) Install new seal in oil pump feed housing with
Special Tool 7888 (Fig. 64).
(2) Install new pickup tube O-ring in oil pump
(Fig. 65).
(3) Prime oil pump by pouring transmission fluid
into pump through pickup tube opening.
(4) Insert pickup tube in oil pump. Then attach oil
screen and connecting hose to pickup tube (Fig. 66).(5) Install assembled pump, pickup tube and
screen in rear case. Be sure screen is seated in case
slot as shown (Fig. 66).
(6) Install magnet in front case pocket.
Fig. 61 Installing Mainshaft And Mode Fork
Assembly
Fig. 62 Installing Drive Chain And Front Output
Shaft
Fig. 63 Installing Mode Spring On Shift Rail
Fig. 64 Oil Pump Seal Installation
Fig. 65 Pickup Tube O-Ring Installation
21 - 302 NP231 TRANSFER CASEJ

(7) Clean sealing surfaces of rear case front case,
retainer and extension. Use 3M all puspose cleaner
or equivalent product.
(8) Apply 3 mm (1/8 in.) wide bead of Mopar gas-
ket maker, silicone adhesive sealer, or Loctite 518 to
sealing surface of front case.
(9) Align and install rear case/oil pump assembly
on front case (Fig. 67). Be sure case locating dowels
are in place and that mainshaft splines are engaged
in oil pump inner gear.(10) Install and tighten front case-to-rear case at-
taching bolts to 27-34 Nzm (20-25 ft. lbs.) torque.Be
sure to install a washer under each bolt used at
case dowel locations.
(11) Install output bearing in rear retainer. Tap old
bearing out of retainer with hammer and brass drift.
Then install new bearing with Tool Handle C-4171
and Installer 5064 (Fig. 68).
(12) Apply 3 mm (1/8 in.) wide bead of Mopar gas-
ket maker, silicone adhesive sealer, or Loctite 518 to
flange surface of rear retainer.
(13) Align and install rear retainer on rear case.
Install and tighten retainer bolts to 27-34 Nzm (20-25
ft. lbs.) torque.
(14) Install new output bearing snap ring (Fig. 69).
Lift mainshaft slightly to seat snap ring in shaft
groove if necessary.
(15) Remove extension housing seal if not removed
previously.
(16) Remove extension housing bushing with Bush-
ing Installer Tools C-4171 and 7889-A (Fig. 70).
(17) Install new extension housing bushing with
Installer Tools C-4171 and 5066 (Fig. 71).
(18) Install new seal in extension. Use suitable
size socket, or installer tool to seat seal.
Fig. 67 Installing Rear Case On Front Case
Fig. 66 Pickup Tube, Oil Screen And Pump
Installation
Fig. 68 Installing Mainshaft Rear Bearing In Rear
Retainer
Fig. 69 Installing Output (Rear) Bearing Snap Ring
JNP231 TRANSFER CASE 21 - 303

(19) Apply 3 mm (1/8 in.) wide bead of Mopar gas-
ket maker, silicone adhesive sealer, or Loctite 518 to
mounting surface of extension housing.(20) Align and install extension on retainer. Then
install and tighten extension bolts to 27-34 Nzm
(20-25 ft. lbs.) torque.
(21) Install new seal on front output shaft (Fig.
72).
(22) Install front yoke on front shaft. Secure yoke
with replacement nut. Tighten nut to 149 Nzm(110
ft. lbs.) torque.
(23) Install replacement gasket on indicator switch
and install switch in case.
(24) Install tighten drain plug to 47 Nzm (35 ft.
lbs.) torque.
(25) Install indicator or vacuum switch in case.
Tighten switch to 27-34 Nzm (20-25 ft. lbs.) torque.
(26) Install speedometer pinion and adapter.
(27) Fill transfer case with recommended lubri-
cant.
(28) Install and tighten fill plug to 41 Nzm (35 ft.
lbs.) torque.
Fig. 70 Removing Extension Housing Bushing
Fig. 71 Installing Extension Housing Bushing
Fig. 72 Installing Seal On Front Shaft
21 - 304 NP231 TRANSFER CASEJ

NP231 TRANSFER CASE
JNP231 TRANSFER CASE 21 - 305

LEGEND FOR NP231 TRANSFER CASE
21 - 306 NP231 TRANSFER CASEJ

NP242 TRANSFER CASE
INDEX
page page
General Information....................... 307
Operating Ranges........................ 307
Overhaul Cleaning and Inspection............ 318
Recommended Lubricant/Capacity/Fill Level..... 307
Shift Lever Installation (XJ)................. 309
Shift Lever Removal (XJ)................... 309
Shift Linkage Adjustment................... 309
Shift Mechanism......................... 307Speedometer Service..................... 309
Transfer Case Assembly................... 319
Transfer Case Changes.................... 307
Transfer Case Disassembly and Overhaul...... 310
Transfer Case Identification................. 307
Transfer Case Installation.................. 309
Transfer Case Removal.................... 309
GENERAL INFORMATION
The NP242 is a full and part-time transfer case
(Fig. 1). It provides full time 2-wheel, or 4-wheel
drive operation. The NP242 is used in XJ models.
A differential in the transfer case is used to control
torque transfer to the front and rear axles. A low
range gear provides increased low speed torque capa-
bility for off road operation. The low range provides a
2.72:1 reduction ratio.
OPERATING RANGES
NP242 operating ranges are 2WD (2-wheel drive),
4x4 part-time, 4x4 full time, and 4 Lo.
The 2WD and 4x4 full time ranges can be used at
any time and on any road surface.
The 4x4 part-time and 4 Lo ranges are for off road use
only. The only time these ranges can be used on hard sur-
face roads, is when the surface is covered with snow and
ice.
SHIFT MECHANISM
Transfer case operating ranges are selected with a floor
mounted shift lever. The shift lever is connected to the trans-fer case range lever by an adjustable linkage rod. Range po-
sitions are marked on the shift knob or shifter bezel plate.
TRANSFER CASE IDENTIFICATION
A circular I.D. tag is attached to the rear case of
each NP242 transfer case (Fig. 2). The tag provides
the transfer case model number, assembly number,
serial number and low range ratio.
The transfer case serial number also represents the
date of build. For example, a serial number of
1-10-94 would represent January 10, 1994.
RECOMMENDED LUBRICANT/CAPACITY/FILL LEVEL
Mopar Dexron II is the recommended fluid for the
NP242 transfer case. Approximate dry fill lubricant
capacity is 1.4 liters (1.48 qts.).
Correct transfer case lubricant level is to the bot-
tom edge of the fill plug hole.
TRANSFER CASE CHANGES
The only service change for 1995 involves the front
output shaft seal which is new. The new seal does
not have the flange used on prior seals and changes
seal installation. The new seal must be seated below
the edge of the seal bore in the front case. Refer to
the overhaul information for seal installation.
Fig. 1 NP242 Transfer Case
Fig. 2 Transfer Case I.D. Tag
JNP242 TRANSFER CASE 21 - 307

NP242 SERVICE DIAGNOSIS
21 - 308 NP242 TRANSFER CASEJ